GFS_QA Manual_2009.pdf

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GFS, LLC. QUALITY ASSURANCE MANUAL

MISSION STATEMENT

We at GENERAL FABRICATING SERVICES, as a quality industrial manufacturer and

contractor, through innovative ideas and services, will provide our value-added expertise and

experience, to meet your project requirements, while continually adapting to the ever-changing

business environment.

COMPANY VALUES

1. To maintain or exceed the highest standards of quality for the products we produce within the

given specifications and expectations of our customers.

2.

To hire, sustain, and maintain open minded, responsive personnel who uphold our companyvalues and have an unbending desire to succeed and fulfill our customer requirements.

3. We will not tolerate laziness, degradation, finger pointing, blaming or any other behavior that

could be described as mediocre and undesirable in our employees.

4. We require all our employees to be free of Drugs and Alcohol at the workplace.

5. We believe our employees should possess an attitude that reflects fairness, honesty, trust,

cooperation and respect in our dealings with each other, our clients, and with other

constituencies.

6. We pride ourselves on having talented personnel who are capable of thinking strategically,

being creative, sharing in the decision making process and seeing themselves as responsible

for all dimensions of our corporate mission.

7.

Our main goal is to continually improve what we do through research, planning and training

to ensure that our company is competitive and seen as an industry leader.

8. We believe that operating as organized, structured, and enthusiastic professionals is

paramount to satisfying our customers needs and maintaining our highest levels of

performance.

9. Our employees will do what ever it takes to meet the time schedules set by our customers

without sacrificing product quality.

10.We do not want to take ourselves so seriously that we forget to have fun, to be able to

celebrate our successes, and to reduce excess stress while meeting our high standards.

11.We expect all of our people to do good work and fulfill their potential, and we will provide

on-the-spot support to ensure that this happens, and when any of our people transcend the

ordinary (work as usual) we will provide appropriate recognition.

12. In order to balance our desire for profitable growth with the obligation to our customers and

employees we will seek to uphold their values in all our transactions.

Quality Assurance Manual

General Fabricating Services, LLC.

# 1 Lewis Avenue

Coraopolis, PA 15108

2002 Edition

www.gfsfab.com

2009 Edition


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Issue and Review Record

Rev. Date Pages Description or Remarks

0 Nov 2, 1998 1 to 17 Initial issue

- Jan 22, 1999 - 1999 Annual Quality Manual Review

1 Nov 29, 1999 15-1 Rev. Section References in Paragraph 15.2.1 & 15.3.1- Jan 13, 2000 - 2000 Annual Quality Manual Review

- Jan 18, 2001 - 2001 Annual Quality Manual Review

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-

-

-

-

-

Jan 11, 2002

Nov 19,2004

Jan 12,2006

Jan 29,2007

Jan 21,2008

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2

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-

-

-

2002 Annual Quality Manual Review

Rev, Mission Statement and Company Values






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Table of Contents

Description Section

Scope and Purpose 1.0

Responsibilities 2.0

Configuration Control 3.0

Purchase Order Control 4.0

Receiving Inspection 5.0

In Process Inspection 6.0

Fabrication Procedures 7.0

Welding Procedures 8.0

Piping Procedures 9.0

Machining Procedures 10.0

Assembly Procedures 11.0

Electrical Procedures 12.0

Refractory Procedures 13.0

Cleaning and Painting 14.0

Inspection Procedures 15.0

Shipping Procedures 16.0


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Miscellaneous 17.0

Page i REV. 0 November 2, 1998

1.0

Scope and Purpose

1.1.Purpose

The purpose of this manual is to define and publish a quality control system for

implementation by GFS

1.2.

Policy

1.2.1. GFS will implement systems and procedures necessary to assure that all

manufactured products and services offered, meet the requirements and standards

established by our management team and customer requirements, to provide a better

product and service to our customers.

1.2.2. This manual is subject to review by customer representatives at any time prior to

issuance of a contract and at all times when a contract is in force.

1.2.3.

Procedures to document and resolve Customer complaints have been establishedin a separate GFS standard.

1.3.Application

The Quality Assurance System defined herein conforms to the requirements of the

GFS Management Team.

1.4.Responsibilities

1.4.1. This manual and supporting documents will be reviewed on an annual basis, and

revised as necessary to ensure conformance.

1.4.2 Revisions will be issued by the Quality Assurance Manager and controlled in

accordance with the applicable procedures.


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Page 1-1 REV. 0 November 2, 1998

2.0 Responsibilities

2.1 The Quality Assurance Team Leader reports to the President of the company in

matters relating to Quality and for manufacturing priorities.

2.1.1. The QA Team (Shop Superintendent and Foremen) will have the authority and

organizational freedom to resolve any quality problems.

2.2 The Quality Assurance Review Board responsibilities include.

2.2.1. Planning how to meet customers quality requirements.

2.2.2. Reviewing customer drawings and specifications.

2.2.3.

Determining inspection points.

2.2.4. Writing inspection and test plans.

2.2.5. Establish and monitor effectiveness of quality program procedures.

2.2.6. Keeping adequate quality assurance records.

2.2.7. Reviewing quality assurance records and overseeing follow-up for correction

and correction of defects.

2.2.8. Assure that supplier quality control and follow-up are adequate.

2.2.9. Coordinating in-plant correction of items rejected by customers, explaining to

customers what action will be taken, and evaluating the actions for

effectiveness.


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2.3 The GFS main office is responsible for establishing job costs, client liaison, in-

process project management and job close out. A standard has been set up for these

procedures.


3.0 Configuration Control

3.1 We manufacture to customer drawings and specifications. Sets of these are filed in

job number folders in our main office.

3.2 Any detail drawings made by GFS, Inc., from customer supplied design drawing

will conform to GFS, CAD standards.

3.3 The main office is responsible for the following:

3.3.1. Charging out and keeping track of drawings and specifications.

3.3.2. Receiving Engineering changes from our customer and sending these changes

to our shop immediately.

3.3.3. Voiding outdated Engineering changes, drawings, and specifications.

3.4 A standard procedure has been set up to control changes by effective date.


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4.0 Purchase Order Control

4.1 When a purchase order is issued to subcontractors, our buyer will send our supplier all

required drawings, specifications, and quality requirements (such as GFS fabrication

terms and conditions, material or process certifications, physical or chemical analysis,

source inspection) with the purchase order. The PO Number and Job Number will be

identified on all material processing.

4.1.1 If there is a drawing or specification change after our order is placed with the

supplier our buyer will send the supplier a purchase order amendment including

our latest Engineering change and the latest drawings or order specifications.

4.2 When a purchase order is issued for raw material, the supplier will issue mill

certification test reports to GFS where they will be kept on file. The PO Number and

Job Number will be identified on all material.4.3 Copies of all purchase orders will be kept on file for our customers to review.


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5.0

UNLOADING, RECEIVING AND IDENTIFYING INCOMING MATERIAL

5.1 The receiver shall determine the contents of incoming shipments from the shipping

papers and will check the items for quantity, damage, incomplete, illegible

identification or identification not in accordance with the shipping papers.

The receiver shall record his findings on the shipping papers and forward them as

required.

5.2 The Foreman shall instruct the receiver on any special handling, storage or

preservation requirements specified on the drawings. The receiver shall follow these

requirements during unloading and storage operations.

All material shall be handled and blocked in a manner to prevent permanent distortion

or damage.

5.3 If the Vendors marking or tagging are complete, legible and in accordance with

Purchase Order requirements, the contract number and Purchase Order number will be

marked on all items.

5.4 Rejected items will be identified and set aside until the Purchasing Department and

Shop Superintendent decides on disposition.

5.5 The Purchasing Department has the responsibility of assuring that a pattern of

continually receiving faulty items from any supplier doesnt develop, and assuring

supplier corrective action.

5.6 Material that is to be cut (sawed, sheared, burned, etc.) for a contract must be verified

by a Purchase Order Number, Contract Number, size, weight, or grade as shown on the

GFS, Inc. cutting list. Material taken from stock must have size, weight and grade

verified before using.


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The Foreman will monitor compliance.

5.7 Any material being returned to GFS stock must have size, weight, and grade marked

on it.



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6.0

INPROCESS INSPECTION

6.1 Item identification shall be maintained at all times. Detail piece marks, sub-assembly

piece marks and/or shipping piece marks must be maintained as applicable. Plant

personnel are responsible for maintenance of identification and Foreman will monitor

compliance

6.2 Material that has been cut (sawed, sheared, burned, etc.) will be dimensionally

checked.

6.3 During Fitting stage of fabrication, dimensional checks will be made routinely per

section 7.2 and customer requirements.

6.4 Foremen will be responsible for visual inspection of product thru out the fabrication

and assembly process per section 15.0.


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7.0

FABRICATION

7.1 Cutters, Drawings and Specifications.

7.1.1 The production personnel will be issued contract specifications, cutters, and

drawings (latest revision) as per contract number and sequence number.

7.1.2 Shop Foreman will see to it that all revised documents are issued immediately to

shop personnel for work on said contract. All previous revisions will be marked

VOID and returned to the shop office. No documents that have VOID

marked on them are to be left on the shop floor.

7.2

Dimensional Tolerances.

7.2.1 The Shop will work to the tolerance as it is shown on the shop detail drawing.

7.2.2 If no tolerances are on the shop detail drawings, the shop will use GFS, Inc.

standard dimensional tolerances.

7.2.3 GFS, Inc. standard dimensional tolerances for welding structural members such as

beams, channels, angles, columns, trusses, etc.

Lengths of 30 ft. or less:

Overall length 1/8

Straightness 1/8 x total length divided by 10

Lengths over 30 ft. to 45 ft.:

Over all length 1/4

Straightness 3/8 x total length divided by 10

Lengths over 45 ft.:

Overall length 3/8

Straightness 3/8 + 1/8 x total length divided by 10


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GFS, LLC GFS, LLC GFS, LLC GFS, LLC GFS, LLC GFS, LLC GFS, LLC GFS, LLC GFS, LLC

7.2.4 GFS, Inc. standard dimensional tolerances for welding a furnace box section.

Width of box 10 ft. or less 1/8

Height of box 10 ft. or less 1/8

Squareness 1/8

Flatness of walls 1/8

Overall length of Box 30 ft. or less 1/8

Width of boxes over 10 ft. to 15 ft. 3/16

Height of boxes over 10 ft. to 15 ft. 3/16

Squareness

3/16


Overall length of box over 30 to 45 ft. 3/16

Width of boxes over 15 ft. 1/4

Height of boxes over 15 ft. 1/4

Squareness (16 & over x 16 & over) 1/4


Overall length over 46 ft. 3/8

7.3 Preparation of Base Metal:

7.3.1 Surfaces on which weld metal is to be deposited shall be smooth, uniform and free

from fins, tears, cracks and other imperfections, which would adversely affect the

quality or strength of the weld. Surfaces that are to be welded, and surfaces

adjacent to a weld, must be free from loose or thick scale, slag, rust, moisture,grease and other foreign materials that would prevent proper welding or produce

objectionable fumes. Mill scale that can withstand vigorous wire brushing, a thin

rust-inhibitive coating or an anti-spatter compound may remain.

7.3.2 In thermal cutting, the equipment will be adjusted and manipulated to avoid

cutting beyond (inside) the prescribed lines. The roughness of all thermal-cut

surfaces shall be no greater than that defined by AWS-C-4-1 (latest revision)

Criteria for Describing Oxygen-Cut Surfaces.


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7.4

Cope and Block Cuts:

7.4.1 All cope cuts and re-entrant cuts will be notch-free and cut to a radius of at least

1/2, unless otherwise shown on shop detail drawings.

7.5 Fit-Up:

7.5.1 The parts to be joined by fillet welds shall be brought into as close contact as

possible. The root opening is not to exceed 3/16 except in cases involving either

shapes or plates 3 or greater in thickness. After straightening and fit-up, if the

root opening cannot be sufficiently closed to meet this tolerance, a maximum root

opening of 5/16 is acceptable, provided suitable backing is used. If the

separation is greater than 1/16, the leg of the fillet weld can be increased by the

amount of the root opening. The separation between faying surfaces of the plug

and slot weld, and of butt joints landing on a backing bar, is not to exceed 1/16.

7.6 Tack Welds:

7.6.1 Tack welds are made by the fitter and or helper to hold assembly together before

final welds are made.

7.6.2

Tack welds are subject to the same quality requirements as the final welds, with

the following exceptions:

A. Preheat is not mandatory for single-pass tack welds that are remelted and

incorporated into the final weld, regardless of whether it is a continuous weld

or a stitch weld.

B. Discontinuities, such as undercut, unfilled craters and porosity need not be

removed before the final weld is made.

7.6.3

Tack welds, which are incorporated into the final weld, will be made with theelectrodes meeting the requirements of the final welds and are to be cleaned

thoroughly.

7.6.4 Fitter will mark the weld size and length on assembled section, regardless of

whether it is a continuous weld or a stitch weld.

7.6.5 Fitter will tack and assemble section in such a manner so that all tacks are in the

welded area.


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7.6.6 Fitter will layout all stitch welds in such a manner as to have a full-length stitch

weld at each end of a weld run.


7.7

Control of Distortion and Shrinkage:

7.7.1 In assembling and joining parts of a structure or built-up member, and in welding

reinforcement parts to members, the procedure and sequence shall be such to

minimize distortion and shrinkage.

7.7.2 All welds will be made in a sequence that will balance the applied best of welding

while the welding progresses.


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8.0

WELDING

8.1 Weld Material (Weld Wire and Gasses) Control:

8.1.1 Welding materials that are ordered for stock (not for a particular contract) and

which have the manufacturers markings required by the AWS. Specification need

not have additional information marked on them, provided they can be traced to

any required material certifications.

8.1.2 Low Hydrogen electrodes will be issued only in quantities that can be used within

the exposure time period specified by the manufacturer or control codes. When a

container is opened, low hydrogen electrodes will be immediately distributed or

placed in holding ovens.

8.1.3 At the end of a shift, or upon completion of welding operations, unused bare

electrodes in the plant will be left on the machine or removed and returned to the

issuance area.

8.2 Welder Qualifications:

8.2.1 All welder qualifications must be as per AWS standards

8.2.2 All welders will be assigned a unique identifying symbol. The Shop

Superintendent will maintain a list of the symbol assignments. It is the Foremansresponsibility to insure that these symbols are regularly and consistently steel-die

stamped, when permitted by the contract specifications, or otherwise identified

adjacent to all welds.

8.2.3 Copies of Welder qualification test reports and Welder performance qualifications

will be maintained and filed by the Shop Superintendent.

8.3 Qualification of Tackers:

8.3.1

GFS, Inc. tackers will be qualified as per AWS qualification of tack welders. PartE, Section 5.43 thru Section 5.52. AWS D1.1 (latest revision)

8.4 Welding standards

8.4.1 All welding to be made in accordance with AWS Dl.1 (latest revision)

8.4.2 All Stud welding to be made in accordance with Chapters 7 and C7 in AWS Dl.1

(latest revision)


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9.0

PIPING PROCEDURES9.1 Procedures for Pipe Installation

9.1.1 Piping information will be obtained from contract documents and drawings. If no

information is available, GFS will use standard practices from The Pipe Fitters

and Pipe Welders Handbook, latest edition, published by Glencoe Publishing

Company.


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10.0

MACHINING PROCEDURES

10.1 Procedures for Machining

10.1.1 Machining information will be obtained from contract documents and drawings.

If no information is available, GFS will use standard practices from The

Machinerys Handbook, latest edition, published by Industrial Press, Inc.


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11.0

ASSEMBLY PROCEDURES

11.1 Assembly criteria

11.1.1 All assembly criteria will be obtained from contract documents and drawings.

This includes, but is not limited to, centerline alignment, chain alignment,

sprocket settings, roll settings, bearing settings, bolting requirements, etc.

11.2 Traceability of assembly items

11.2.1 All free-issue items supplied by the customer must be tagged with purchase order

number, drawing number, and item number. (All operations manuals receivedwith customer supplied free-issue items, will be packaged and shipped to field

with free issue item).

11.2.2 All assembly items purchased by GFS, Inc. will be tagged with GFS purchase

order number, contract number, drawing number, and item number.

11.3

Disassembly

11.3.1 Shop assembled items will be disassembled per customer requirements and

shipping limitations.


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12.0 ELECTRICAL PROCEDURES

12.1 Procedure for electrical installation

12.1.1 All electrical specifications and information will be obtained from the contract

documents and drawings. If this information is not available, GFS will use the

codes and procedures found in:

12.1.1.1 USA - The National Electrical Code, latest edition published by The

National Fire Protection Association.

12.1.1.2 Canada - The Canadian Electrical Code, latest edition.

12.1.2 If Customer documents do not specify, GFS will use standard ridged conduit,

standard flexible conduit, standard wire and standard junction boxes.


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13.0

REFACTORY PROCEDURES

13.1 Procedures for the installation of refractory

13.1.1 All refractory specifications (installation instructions, material type, expansion

joints, stud patterns, etc.) will be obtained from the contract documents and

drawings. If this information is not available, GFS will use procedures that are

recommended by the refractory manufacturer and approved by the customer.


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14.0

CLEANING AND PAINTING PROCEDURES

14.1 Cleaning and Painting

14.1.1 Surface preparation on contract work shall be done in conformance with the

required SSPC specification called for in the contract documents and drawings.

(GFS standard surface preparation is, SSPS SP3, Power Tool Cleaning)

14.1.2 The paint material shall be stored in an enclosed shop area. Application shall be

consistent with the coating instructions and the manufacturers recommendations.

14.1.3 Prior to shipment, all items shall be cleaned, painted, packaged, and loaded in

accordance with instructions specified in the contract documents and on the shop

drawings. If no special instructions are given, good shop practice shall be

followed to prevent damage, deterioration, or loss of items during shipment.


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15.0

INSPECTION PROCEDURES

15.1 General

15.1.1

Fabrication inspection and tests shall be performed by the Quality

Control/Production Team as necessary prior to, during, and after all stages of

fabrication to ensure that materials and workmanship meet the requirements of

contract documents. Verification, inspection and testing shall be performed and

their results reported to the owner and contractor in a timely manner to avoid

delays in the work.

15.1.2

Inspection procedures supplied in the customers original contract documents will

take precedence in all stages of fabrication. If no inspection procedures are given,

GFS will use the inspection procedures described in this Quality Control Manual.

15.2 Fabrication

15.2.1 Dimensional inspections will be performed in accordance with the Procedure for

Fabrication (Section 7.2) of this manual.

15.3 Welding

15.3.1 Visual welding inspection will be conducted in accordance with the Welding

Procedures (Section 8.4) of this manual.

15.3.2 If Hydro-Static testing procedures are not spelled out on shop drawings or job

specification, but are required, GFS will use the following procedures:

15.3.2.1 Remove dirt, grease, and weld spatters in seams that are to be tested.

15.3.2.2 Visually inspect for defects and repair as required


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15.3.2.3 Attach the proper pipes, plugs, and gauges

15.3.2.4 Pressurize to fifty (50) pounds of air pressure

15.3.2.5

Splash a detergent/water mixture over welds that are to be tested:

15.3.2.5.1 If leaks show, mark and release pressure

15.3.2.5.2 Grind repair area and reweld (must be qualified welder).

15.3.2.5.3 Retest weld

15.3.2.6 Fifty (50) pounds of air pressure is to be held for _ hour. Foreman is to

witness start and finish of holding period.

15.3.2.7 Foreman is to document test and give results to the shop superintendent.

15.3.3 Dye penetrant testing will be done on all gas tight welds that are accessible from

both sides using the following method:

15.3.3.1 The weld will be visually checked for any potential leaks and a qualified

welder will make repairs at the time.

15.3.3.2

All dirt, grease, weld spatter, slag, and loose scale will be removed.

15.3.3.3 The developer will be applied on the gas tight side of the weld.

15.3.3.4 The penetrant will be applied liberally on the opposite side of the weld.

15.3.3.5 If a leak appears

15.3.3.5.1 Repair area will be marked

15.3.3.5.2 Repair area will be ground or gouged

15.3.3.5.3 Repair area will be rewelded by a qualified welder

15.3.3.5.4

Steps 15.3.3.1 to 15.3.3.4 will be repeated to retest the weld.

15.3.4 Dye penetrant testing will be done on all gas tight welds that are accessible from

only one side using the following method:



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15.3.4.1 The weld will be visually checked for any potential leaks and a qualified

welder will make repairs at that time.

15.3.4.2 All dirt, grease, weld spatter, slag, and loose scale will be removed.


15.3.4.3

The penetrant will be applied to the weld and allowed to work into any

weld imperfections for fifteen minutes

15.3.4.4 The penetrant will then be removed

15.3.4.5 The developer will be applied over the weld surface

15.3.4.6 If a leak appears

15.3.4.6.1 Repair area will be marked

15.3.4.6.2 Repair area will be ground or gouged

15.3.4.6.3 Repair area will be rewelded by a qualified welder

15.3.4.6.4 Steps 15.3.4.1 to 15.3.4.5 will be repeated to retest the weld.

15.4 Assembly

15.4.1 Any inspection on assembled items will be done by the customer or by GFS in

accordance with instructions supplied by the customer.

15.5 Machining

15.5.1 The general shop foreman will inspect machined pieces in accordance with the

dimensional tolerances shown on the contract documents and drawings.

15.6

Piping

15.6.1 The pipe foreman will perform dimensional inspections on pipe assemblies in

accordance with contract documents and specifications.


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15.6.2 Any leak testing will be done in accordance with contract documents and

specifications. If no testing criteria is given, GFS will use one of the testing

methods described in section 15.3 of this manual.


15.6.3 Large, multi threaded connected pipe assemblies will not be pressure tested due to

the inability to prevent the vibration during transit from loosening the connection.

15.7

Electrical

15.7.1 Any inspection on electrical items will be done by the customer or by GFS in


15.8 Refractory

15.8.1

Any inspection on refractory items will be done by the customer or by GFS in


15.9 Painting

15.9.1 The initial paint inspection will be a visual inspection to check for runs, sags, light

spots, and missed spots. Appropriate corrective measures will be taken for any

imperfections that are found.

15.10Inspection Documentation


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15.10.1 All gas tight weld testing and pressure testing will be documented on the

appropriate form and signed by the Quality Control/Production Team member and

forwarded to the Shop Supervisors office.

15.10.2 Each department will use the standard inspection report to document inspection

and repairs, if any. The report will be signed by the Quality Control/Production

Team member and forwarded to the Shop Supervisors office.


15.10.3 Any special inspection witnessed or performed by the customer or his

designated representative will be documented on the appropriate form, signed by

the Quality Control/Production Team member and the customer representative

then forwarded to the Shop Supervisors office.

15.10.4 At completion of job, all forms will be placed in the Job folder at the Main

Office where they will be stored for a period of 2 (Two) years.


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16.0

SHIPPING PROCEDURES

16.1 Piece Marking

16.1.1 All pieces that are to be shipped will be properly identified in accordance with the

marking instructions found in the contract documents and drawings. The shop

foremen will monitor compliance.

16.2 Shipping papers

16.2.1 All shipping papers will be completed in accordance with the instructions found

in the contract documents and drawings. The shop foremen will insure that what

is listed on the shipping papers corresponds to what is loaded on the truck.

16.3

Bracing

16.3.1 All fabricated members will be braced for shipping in accordance with

instructions found in the contract documents and drawings. If no bracing


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instructions are given, GFS will use good shop practice to provide sound bracing

for shipment.

16.4

Refractory

16.4.1 All refractory shipped (either loose or installed in a fabricated structure) will be

100% tarpped regardless of distance to be traveled or predicted weather

conditions.


16.5 Lifting Lugs

16.5.1 Customer approved Lifting lugs may be installed on fabricated structures in order

to aid in loading. Lifting lug placement will be done in such a way as to avoid

any distortion during lifting.

16.6 Tie Down Points

16.6.1 Tie down points will be determined in such a way as to avoid any distortion in

transit. GFS and the trucking company responsible for the load will agree upon

tie down points.


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17.0

Miscellaneous

17.1 The Quality Assurance Team, thereto, will determine control of manual and Quality

Control forms and changes.

17.2 Security of welders stamps will be the responsibility of the shop superintendent.

17.3 These stamp records will be made available to customers upon request.


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